SAMPE Journal - July/August 2020 - 14
FEATURE / COMPOSITE WING MOVEABLES
Table 2. Integrated flap concepts.
SQRTM offers a significant cost reduction compared to the black metal solution with hand lay-up
and autoclave (-20%). Indeed, this level of integration enables to save time and cost on the manufacturing of the primary parts (less curing cycle) and
on the final assembly (less fasteners).
In order to mitigate risks, we have followed a
building blocks approach. After the manufacturing
of a series of flap components in SQRTM with manual lay-up of prepreg fabric, SONACA developed
design concepts using UD tape materials to combine the high speed of automated lay-up and the
integration capability of SQRTM. The first step
towards more integrated flap was the manufacturing of 3 demonstrators (1,2 m) with the cocuring of
both spars to the lower skin.
The CFRP material used was UD tape 8552/
AS4. Each spar was composed of a C and Z preforms. The preforms of the spars and the blade
stiffeners were draped flat with ATL and then hotformed under vacuum. The skin was also draped
with ATL. The preforms were then inserted into
the SQRTM mould and cured in a press with the
injection of 8552 resin to apply pressure on the
part. After demolding, the inspection of the part
(visual, US, dimensional and micrography) showed
the high quality of the part. All thickness measurements (32 control points) were within the tolerance
(-8%/+10%). The internal quality was very good as
shown on the US C-scan and micrography.
A manufacturing trial was performed to integrate a rib in addition to the spars. If the SQRTM
process showed the capability to perform such an
integration, this integration route was not pushed
further based on the cost analysis which reveals
that integrating the ribs does not offer any significant cost savings.
14
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SAMPE JOURNAL
|
Figure 11. Weight and cost analysis of the integrated flap concepts.
Figure 12. Lower skin demonstrator with cocured spars (1,2 m).
Figure 13. C-scan and micrography from the lower skin demonstrator with
cocured spars.
Figure 14. Lower skin demonstrator with cocured
spars and rib (1,2 m).
J U LY/AU G U S T 2 0 2 0
w w w. s a m p e . o r g
http://www.sampe.org
SAMPE Journal - July/August 2020
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